DocumentTitle:FunctionGroup:InformationType:Date: Hydrauliccylinders, dieseling 091 ServiceInformation8/4/2020
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Hydrauliccylinders,dieseling
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Ifairentersthehydrauliccylindersduringworkonthehydraulicsystem,thiscanleadtospontaneousignition,aneffectknown asdieseling.Thisoccursifafavourablemixtureofairandhydraulicoiliscompressedwhenthepistonapproachesitsend positioninthecylinder.Asufficientlyhightemperaturecanbereachedforthemixturetospontaneouslyignite.
NOTICE
Thedieselingeffectmayresultinburntpistonsealsandbushings.
Inordertopreventdieseling,thelinesforthehydrauliccylindersmustbebledafterworkiscompleted,asfollows:
1. 2. Noloadandkeepthelowestenginerpm
Operatethepistonslowlyuptothemiddleofcylinderinordertoremoveairfrominnerchamberofcylinder.Repeat over5times.
Afterthat,operatethepistonuptotheendofcylinderinordertoremoveresidualairfromcylinder,pipeandhose gradually.Repeatover5times.
NOTICE
Ifthecylindersarepressurizedeitherthroughliftingofthemachineorliftingofaloadinthebucket,withoutfirst performingthementionedbleedingmovements,thesealswilllikelybedamaged.
Ifacylinderistobepressure-testedafterarepair,thepistonrodshouldberuninandoutafewtimesbeforeincreasingthe pressuretotestingpressure.
DocumentTitle:FunctionGroup:InformationType:Date: Machineview 000 ServiceInformation8/4/2020
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EC170DVolvo
Machineview
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Figure1 Machineview
1Dipperarmcylinder 14Trackmotorandgearbox
2Boom 15Hydraulictank
3Boomcylinder 16Fueltank
4Operatorcab 17Upperroller
5Chargedaircooler,hydraulicoilcoolerandradiator18Turningjoint
6Swingmotorandgearbox 19Bottomroller
7Aircleaner 20Idler
8Maincontrolvalve 21Bucket
9Engine 22Link
10Rearhood 23Bucketcylinder
11DieselParticulateFilter(DPF) 24Dipperarm
12Counterweight 25Swingringgear
13Mainpump
DocumentTitle:FunctionGroup:InformationType:Date: Productplates 000 ServiceInformation8/4/2020
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EC170DVolvo
Productplates
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Pleaserefertothefigurebelowtolocatetheproductplate,engineplate,cabplateandattachmentplates.Alwaysusethe ProductIdentificationNumber(PIN)providedonthevehicleand/orengineplatesfortroubleshootingpurposesand/orwhen orderingspareparts.
Productplate
ThisplatewithProductIdentificationNumber,PIN,forthecompletemachineindicatesthemodeldesignation,serialnumber andwhenapplicable,machineweight,enginepower,manufacturingyearandCEapproval.Theplateispositionedontheright sideoftheupperframe.
Engine
Theenginetypedesignation,partandserialnumbersarestampedonthetopofvalvecover.
Attachmentquickcoupler
Thisnameplateisattachedontheoutsideofthebracketandindicatesthepartnumberandweight.
Bucket
Thisnameplateisattachedonthetopofthebucketandindicatesthebucketmodelordernumber,serialnumber,bucketpart number,ratedcapacity,weight,cuttingwidth,toothpartnumber,andadapterpartnumber.
Cab
Thenameplateisattachedontheinsideofthecabandindicatestheproductnumber,serialnumber,modeltype,andweight.
DocumentTitle:FunctionGroup:InformationType:Date: Servicepositions091 ServiceInformation8/4/2020
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EC170DVolvo
Servicepositions
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Parkthemachineonahorizontalandfirmsurface. Thesuitablepositionisindicatedinthedescriptionforthevariousservicejobs. Beforebeginninganyworkonthemachine.
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Turnofftheengineandremovetheignitionkey. Depressurizeallpressurizedlinesandpressurevesselscarefullysothathighpressureisreleasedwithoutrisk. Allowthemachinetocooldown.
ServicepositionA
ServicepositionB
Figure1
Figure2
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ServicepositionC
ServicepositionD
ServicepositionE
ServicepositionF
Figure3
Figure4
Figure5
Figure6
DocumentTitle:FunctionGroup:
InformationType:Date: Weldingonthemachine091 ServiceInformation8/4/2020
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EC170DVolvo
Weldingonthemachine
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EC170DVolvo NOTICE
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Duringelectricweldingonthemachineorattachmentsconnectedtothemachine,componentssuchasbearingsand electricunitsmaybedamagedifthegroundcableisconnectedincorrectly.
Thefollowingactionsshouldbetakenbeforestartingelectricweldingtoeliminatetheserisks:
Turnofftheelectricpowerusingthebatterydisconnector.
Disconnectthebatteries.
NOTE!
Boththeplusandminusterminal.
Disconnectthefollowingelectronicunits:
–Vehicleelectroniccontrolunit(V-ECU)
–Engineelectroniccontrolunit(E-ECU)
–Instrumentelectroniccontrolunit(I-ECU)
–Electronicclimatecontrolunit(ECC)
–Wipercontrolunit(CU3601)
Connecttheweldingunit'sgroundconnectionascloseaspossibletotheweldingpoint,andmakesurethatthecurrent doesnotpassacrossabearing.
Ifweldingisnecessaryontheboomordipperarm,thefollowingbasicrulesshouldbefollowed:
Weldingbeadsshouldbelaiddowninthelongitudinaldirection.
Ifpossible,weldinthemiddleofthemetalsectionandnevercloserthan80mmtoanedge.
Donotweldneartheweldedconnectionsofthecylindermountingeyes.Minimumdistancefromeye'sweldtoweldfor weldlug=100mm
Donotweldclosetowhereametalplatehasbeenbent.
1. 2. 3.
DocumentTitle:FunctionGroup:InformationType:Date: Bearings 170 ServiceInformation8/4/2020
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EC170DVolvo
Bearings
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Removal
Bearingsshouldneverberemovedunlessabsolutelynecessary.Alwaysusetherecommendedpullertoreducetheriskof bearingorrelatedcomponentdamage.
Whenbearingsorbushingareremoved,checkthatthebearingsisfreefromdiscoloration,nicks,scuffingandsignsof overheating.Ifindoubt,replacethebearingorbushing.
Cleaning
Bearingsacceptableforserviceshouldbecleanedinasuitablesolventandimmersedinacleanlubricatingoiluntilneeded.
Installation
Besurebearingsareinstalledwithcareduringservicing,maintenanceandrepair.Allbearingsonthismachineareinstalledasa pressfit.
Whenpossible,alwaysinstallthebearingintotherotatingpartfirst.Usethepropertoolsorapresswheninstallingabearingor bushing.
Intheabsenceofthepropertoolsorapress,coolthebearingsand/orheatcasingtoassistintheinstallation.
DocumentTitle:FunctionGroup:InformationType:Date: Cleaningpriortorepair170 ServiceInformation8/4/2020
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EC170DVolvo
Cleaningpriortorepair
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Cleantheexteriorofallpartsbeforerepairing.Dirtandabrasivedustreducetheefficientworklifeofthepartandleadtocostly replacement.
Usecleaningfluidsandsolventswhicharesuitableforcleaningpartsanddonotriskthesafetyoftheuser.Certaintypesof fluidsdamagerubberpartsand/orcauseskinirritation.
Thefollowingprecautionsmustbeobservedtoinsurehydrauliccleanliness:
Flushhoseandtubeassemblieswithasolventcompatiblewithhoseassemblies.Blowoutexcesssolventwithshopair. Caphydraulicfittingsandprotectthreadsuntilinstallation. Caphosesandtubeassembliesuntilinstallation.
Flushhydraulicreservoir,fueltankandchaincasehousingswithasuitablesolventtoremoveanyforeigndebris. Protectsystemcomponentsfromairbornecontaminants.Plugallcylinder,valve,reservoir,tankandpumpopenings untilinstallation.
Useclean,filteredmotoroilwhenfillingthesystem.SeeRecommendedlubricants
DocumentTitle:FunctionGroup:InformationType:Date: Hosesandtubes170 ServiceInformation8/4/2020
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EC170DVolvo
Hosesandtubes
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Inspection
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Ifthehoseendconnectionsaredamaged,alwaysreplacehosesandtubes.Damaged,dented,crushedorleakinghosefittings restrictoilflowandtheoperationofthepartsbeingserved.
Besurehosesareingoodcondition.Ifindoubt,replacethem.
Replacehosesifthefollowingoccur:
chafedoutercover concealedcorrosionofwirereinforcement ballooning(replaceimmediately!) kinked,crushed,stretchedordeformed.
Installation
Wheninstallinganewhose,looselyconnecteachendandtakethedesignedpositionbeforetighteningtheconnection.Hoses mustbetightenedusingtwowrenches.Oneisusedtotightentheswivelnut,theothertoensurethehoseflexiblepartisnot twisted.Clampsshouldbetightenedsufficientlytoholdthehosewithoutcrushingandtopreventchafing.
Ifahoseisreplacedonamovingpart,besureitdoesnotfoulbymovingthepartthroughitscompleterangeoftravel.
Besureanyhosewhichhasbeeninstalledisnotkinked,twistedorexposedtoanysharpedges.
Freemoving,unsupportedhosesmustnevertoucheachotherorrelatedworksurfaces.Thiscauseschafing,reducinghoselife.
DocumentTitle:FunctionGroup:InformationType:Date: Pressuretesting170 ServiceInformation8/4/2020
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Pressuretesting
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Priortopressuretesting,besureallhosesareingoodconditionandallfittingsaretight. Useapressuregaugewitharangethatishighenoughtomeasurethespecifiedpressure. Complywiththecorrectproceduretopreventdamagetothesystemortheequipmentandtoeliminatethepossibility ofinjury.
DocumentTitle:FunctionGroup:InformationType:Date: Replacementparts170 ServiceInformation8/4/2020
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EC170DVolvo
Replacementparts
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Forreferencewhenorderingreplacementpartsormakingserviceinquires,recordthemodelandserialnumbersofyour machine.
Theyarestampedontheserialnumberplatepositionedundertheboomonthesuperstructureframe.
DocumentTitle:FunctionGroup:InformationType:Date: Safetywhenservicing170 ServiceInformation8/4/2020
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EC170DVolvo
Safetywhenservicing
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EC170DVolvo
ForSafetywhenservicing,seetheSafetySection,SectionS.
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DocumentTitle:FunctionGroup:InformationType:Date: Servicemethods170 ServiceInformation8/4/2020
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Servicemethods
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Appropriateservicemethodsandproperrepairproceduresareessentialforsafe,reliableoperationofthemachinesandsafety oftheindividualdoingthework.ThisServiceManualprovidesgeneraldirectionsforaccomplishingserviceandrepairworkwith tested,effectivetechniques.Followingthemwillassurereliability.
Therearemanyvariationsinprocedures,techniques,toolsandpartsforservicingmachines,aswellasworkskills.Thismanual cannotpossiblyanticipateallsuchvariationsandprovideadviceorcautionsforeachone.Accordingly,anyonewhointendsto departfromtheinstructionsinthismanualmustfirstconsiderpersonalsafetyandthenmachineintegrity.
NOTE!
VolvoCErecommendstheuseofenvironmentallysoundwastestorageanddisposalpractises.Neverdrainfluidsontheground orintoasewerorcatchbasin.Usesuitablecollectioncontainers,thenstoreand/ordisposeofwasteproductsinanapproved andsafemanner.Checkandobeyallfederal,stateand/orlocalregulationsregardingwastestorage,disposalandrecycling.
DocumentTitle:FunctionGroup:InformationType:Date: Service 170 ServiceInformation8/4/2020
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Service
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Forthemachinetooperatesafelyandatthelowestpossiblecost,itmustreceivethoroughandcompletemaintenance.Intervals formaintenanceandlubricationrefertonormaloperatingandenvironmentalconditions.Maintenanceworkisdescribedinthe Operator'smanualandthemanual"Serviceandmaintenance"aswellastheServiceprogram.
ServiceProgramme
Thecheckingboxesintheserviceprogramshowwhattypeofserviceshouldbedoneforintervalsfromevery10hoursuptoand incl.4000hours.Theserviceintervalsfromandincl.4500hoursonlycontaintheadditionalservicepointsthataretobedoneat eachinterval.
Theadditionalservicepointsthataretobedoneatthefirst500hoursarepresentedinthesameway.
TimeGuide
TheTimeGuideforserviceintervalsforevery10hoursuptoandincl.4000hoursshowstimeforthetotalservice.Intervalsfrom andincl.4500hoursonlyshowtimefortheadditionalservicepoints.
Example,4500hourinterval:
Doallmaintenanceaccordingtothestandardintervalevery500hoursandalsodotheextrainterval4500hours. Followthesameexampleatthefirst500hours.
DocumentTitle:FunctionGroup:InformationType:Date: VCADSPro,Operations170 ServiceInformation8/4/2020
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EC170DVolvo
VCADSPro,Operations
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ThefollowingVCADSProoperationsareavailableforfunctiongroup1.Operationsusedwhenchangingorworkingon componentsaremandatory.
Tests
Operation Application
17012-3Errorcodes Usedwhenthereisasuspicionoffaultand/oratabnormalvalues/ readings.
17034-3Vehicleinformation,test Readoutvehicleinformation
Programming
Operation Application
17030-3,ParameterprogrammingWhenchangingparameters.
17055-3Centralsystems,updating,replace controlunit WhenreplacingECUbyconversionkit.
17056-3Centralsystems,updating,change software Whenreplacingsoftwarebyconversionkit.
17095-3Handlecomponent
Whenreplacingthecompleteengine. ThisoperationistoupdatemachinedatainVolvo’scentralsystems.
DocumentTitle:FunctionGroup:InformationType:Date: Basiccheck,Engine210 ServiceInformation8/4/2020
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EC170DVolvo
Basiccheck,Engine
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NOTE!
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Certaintestsandchecksareperformedwithunlockedsafetylockinglever.Makesurethatthemachinecannotoperate unexpectedlywhenthecontrollockoutleverisunlocked.
Purposeofthebasiccheck
Thepurposeofthebasiccheckistoprovidefastandaccurateinformationaboutthegeneralconditionoftheengine. ThebasiccheckshouldbeperformedandevaluatedaccordingtoinstructionsinthePC-toolVCADSPro.
Testsincludedinthebasiccheck
Thebasiccheckwhichisdividedintothefollowingtestsshouldbeperformedafterreadingouterrorcodesandchecking parameters.
Tests:
Cylindercompression,test
Thepurposeofthetestistoshowifanycylinderhasadeviatingcompressionpressure.Thetestreplacestheold pressurecheckmethodbutdoesnotgiveanyabsolutevalues.
Feedpressure,test
Thepurposeofthetestistocheckthatthefeedpressureisasperspecification.
Sensor,test
Thepurposeofthetestistocheckthefunctionofallsensors.
DocumentTitle:FunctionGroup:InformationType:Date: Camshaft,description215 ServiceInformation8/4/2020
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EC170DVolvo
Camshaft,description
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Thecamshaftiscarriedinsevenbearings.Theaxialstopforthecamshaftislocatedinthetiminggearcasing'scover. Onthecamshaftgearthereareseventeethpressedinforthecylinderpositionsensor. Eachbearingrunsinabearingbushingwhichispressedintothecylinderblock.Thereisaninletcamandanexhaustcamfor eachcylinder.Therearealsotwocams(1)withthreecamlobesfortheinjectionpumps.
Figure1
DocumentTitle:FunctionGroup:InformationType:Date: Chargeaircooler, description 258 ServiceInformation8/4/2020
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EC170DVolvo
Chargeaircooler,description
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Thefunctionoftheintercooleristolowerthetemperatureoftheairbeforeitispressedintotheengine'scylinders.
Turbochargingoftheengine,whichmeansthattheturbochargerpressesairintothecylinders,increasestheairtemperature. Whentheairiscooledaftertheturbo,theairvolumedecreasesandmoreair(oxygen)canbepressedintothecylinders.
Thiscoolingiscalledcharge-aircooling(intercooling)andmakesitpossibletoinjectmorefuelintothecylinders,whichresults inasignificantpowerincrease.
Theintercoolerlowerstheairtemperaturebyapprox.100°C(212°F)andthisincreasesenginepowerbyapprox.10%.The enginetorqueisalsoincreasedandfuelconsumptionisreduced.
Aturbochargeddieselenginewithcharge-aircooling(intercooling)hasthehighestefficiencyofallcombustionengines.
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Connectingrod,description216 ServiceInformation8/4/2020
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Connectingrod,description
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Theconnectingrod,madeofforgedsteel,isprovidedwithabalancingweight(A)atthecrankshaftbearing(big-end)to compensateformanufacturingtoleranceswithregardstoweightandthepositionofthecentreofgravity.
Thenumbermarkingsatthecrankshaft(big-end)bearingendandonthecrankshaftbearingcapmustfaceinthesamedirection andmusthavethesamenumber.
Guidelugsintheupperandlowerbearingshellspreventrotationinthebearingposition.
Thepistonmustbefittedsothattheflywheelsymbolonthepistontopfacestheflywheel.
Figure1
DocumentTitle:FunctionGroup:InformationType:Date: Coolingfancontrol263 ServiceInformation8/4/2020
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EC170DVolvo
Coolingfancontrol
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Hydraulicoilcoolingsystem
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Thefunctioncontrolscoolingfanspeedaccordingtotheinputfromthehydraulicoiltemperaturesensor.
Inputsignals
PinNo.
VA40 V-ECU
Outputsignals
PinNo.
VA9 V-ECU
Functiondescription
Description
Hydraulicoiltemperaturesensor,SE9105
Hydraulicoilfanmotorproportionalvalve
Ifthehydraulicoiltemperatureisbelow60°C,theoutputcurrentwillbethemaximumcurrent.Themaximumcurrentwillcause lowoilflowviatheproportionalvalvetothecoolingmotorinportandreducecoolingfanrpmtohalfspeed.
Figure1 Fanspeedcontrolcurve
A. B. C.
D.
Maximumcurrent
Fullspeed
Halfoffullspeed
Minimumcurrent
a. b. Expectedrotatingspeedofcoolingfan
Currentforhydraulicoilfanmotorproportionalvalve
Ifthehydraulicoiltemperatureishigherthan90°C,theoutputcurrentwillbetheminimumcurrent.Theminimumcurrentwill causefulloilflowviatheproportionalvalvetothecoolingmotorinportandincreasecoolingfanrpmtomaximumspeed.
Seealso,Hydraulicoilcoolingsystem,description
DocumentTitle:FunctionGroup:InformationType:Date: Coolingsystem,component location 260 ServiceInformation8/4/2020
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Expansiontank
Chargeaircoolerhose
Fanguard
Radiatorassembly
Hydraulicoilport
Radiatordrainvalve
Thermostat
Radiatorhose
Staybar
Figure1
Coolingfan
Coolantpump
Engineoilcooler
Description
Coolingsystem,description
DocumentTitle:FunctionGroup:InformationType:Date: Coolingsystem,description260 ServiceInformation8/4/2020
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EC170DVolvo
Coolingsystem,description
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Thecoolingunitcellsandtanksaremadeofaluminium.Thehydraulicoilcoolerandthechargeaircoolerareinstalledtothe radiatorframe.
Airisdrawnintotheenginecompartmentpassingthroughtheradiator,theoilcoolerandthechargeaircoolerasthefan rotates.
DocumentTitle:FunctionGroup:InformationType:Date: Crankcaseventilation, description 212 ServiceInformation8/4/2020
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Crankcaseventilation,description
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EC170DVolvo
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Sincesomeofthecombustionpressureentersthecrankcaseafterpassingbythepistonsandpistonrings(blow-by),the crankcasemustbeventilated.
Thepurposeofthecrankcaseventilationistobalancethepressureinthecrankcaseinordertoavoiddamagetoengine componentsandtopreventoilmistformationandoilleakageintotheambientair.
Thecrankcaseventilationconsistsofahousingcontainingafilter,withconnectionstotheoilsumpandventilationpiping.
Figure1
Crankcaseventilationhousing
Aircontainingoilparticlescomesfromthecrankcaseviathecylinderheadintothecrankcaseventilator.Theair(bluearrows) passesthroughthefilter,whileoilparticles(redarrows)arecaughtandledbacktotheoilsumpviaareturnpipe.
Supplementaryinformation
Engine,description
Lubricationsystem,componentlocations
DocumentTitle:FunctionGroup:InformationType:Date: Crankshaft,description216 ServiceInformation8/4/2020
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EC170DVolvo
Crankshaft,description
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Theforgedcrankshaftisprovidedwithintegratedbalancingweights.Thegearthatdrivestheengine'stiminggearandthe flangefortheflywheelareshrink-mountedonthecrankshaft.
Figure1
DocumentTitle:FunctionGroup:InformationType:Date: Cylinderblock,description212 ServiceInformation8/4/2020
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EC170DVolvo
Cylinderblock,description
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EC170DVolvo
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Thecylinderblockiscastinonepieceandhaswet,replaceablecylinderlinings.Combustionpressuretensilebreakingstrengthin cylinderheadscrewsisledthroughstiffenedsectionsofthecylinderblockwalldirectlytothemainbearings.
Thecylinderblocksurfaceshouldnotbegroundasthedistancebetweenthepistonsandthevalveheadsmaybecometoo small.Thereisalsoariskthatinjectortipswillbeincorrectlyplacedinrelationtothepistonsandthatexhaustvalueswillworsen.
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